Elastic pile fabric and method



March 6, 1962 J. H. HILL ELAsTIc PILEFABRIC AND METHOD 2 Sheets-Sheet 1 Filed Aug. 4, 1958 A 'TTORNEY "f/ INVENTOR. ./oHN H HILL March 6, 1962 J, H. HlLL 3,023,596

ELASTIC PILE FABRIC AND METHOD Filed Aug. 4, 1958 2 Sheets-Sheet 2 INVENTOR. Jol-1N H. H/Lz.

A TTORNE Y States heb This invention relates to a method of knitting and to knitted pile fabrics and more particularly, to such fabrics in which the pile is comprised as tufts of staple fibers drawn with loops of a base fabric in which an elastic yarn is incorporated to render the fabric extensible and to assist in retaining the tufts in place.

It is a general object of the invention to produce a fabric of the type having so-called Hi-Pile which shall be stretchable or extensible in at least one direction and in which the pile tufts will be securely held in place when the fabric is extended as well as When it isrelaxed.

A further object is that of forming such fabrics in which desired elasticity may be realized with a minimum of elastic yarn.

Another object is that of knitting to form a product having a relatively dense pile or cover and to accomplish that without forming a tuft at each loop.

A still further object is that of knitting such a fabric in a simple, inexpensive and expeditious manner and of preserving the better characteristics of such pile fabrics while rendering them elastic.

Other objects will appear from the following more detailed description.

Very attractive and serviceable pile material is now knitted rather extensively in the trade by feeding to the needles fibers usually taken in the needle hooks from a sort of card dofiing cylinder just before those needles engage a yarn which is to form a backing or base fabric. These fibers are normally supplied in sliver form and are referred to as staple or staple fibers. They may be of varying length and weight but as each needle takes a tuft of them in its hooks and then is drawn down to take and to knit the base yarn, they are drawn or looped along with that base yarn, but also have their free ends projecting to the back of the fabric. Finishing them affects them in such a way as to cause them to project uniformly, to stand erect and to take on a very attractive appearance which may be varied depending upon the purpose to which the material is to be put. However, in all uses to which such materials have been put no appreciable elasticity or extensibility has been provided, Of course, there are many end products for which a high quality pile material is demanded and wherein one would also like a wide degree of extensibility and contraction, at least in one and often in two directions.

According to the invention, the fabric may take several forms but primarily it comprises a base fabric of comparatively non-elastic yarn knitted at some or all wales of the courses and having tufts of fibers incorporated at some at least of the loops in all or spaced courses. In addition, an elastic yarn is incorporated in some wales and courses of the fabric. It is either knitted in or laid in so as to be held, preferably at spaced wales and also is so placed along with the pile tufts that it aids mate rially in holding those tufts securely in place even though the fabric mesh may be opened appreciably as the sarne is stretched, either in one direction or both laterally and lengthwise.

In knitting these fabrics, a multifeed, independent needle knitting machine may be utilized and the staple or other fibers are fed and are parallelized and properly presented to the needles by a card means or, more particularly, the doffer cylinder thereof.v Needles may be divided in any convenient way so some only take the atent O 3,023,596 Patented Mar. 6, 1962 fibers. A11 preferably take the base yarn after some, at least, have taken bers and then knit. At what amounts to a separate feeding station spaced needles are ralsed after drawing their yarn and fibers into the fabric and receive an elastic yarn of anyvsuitable type which they may then draw into stitches. These, of course, contract very noticeably, but do impart to the fabric considerable extensibility in either direction. As will be explained, these elastic yarn loops contract or draw up the fabric and help to hold the fibers of the pile tufts in place.

In a second form the invention may take, the elastic yarn is fed in advance of the feeding of the fibers and base yarn and is so introduced as to be laid in at spaced wales and, if desired, at spaced courses. It, likewise, contracts and aids very materially in maintaining the pile in place, even as the fabric may be extended to a considerable degree.

The invention will be described in greater detail by reference to specific embodiments thereof as shown in the accompanying figures of drawing, wherein:

FIG. 1 is a perspective view of a section of fabric greatly enlarged and also shown considerably more open than it actually would be in practice, according to one form thereof in which the elastic yarn is knitted.

FIG. 2 is a similar view, but illustrating a different sequence of incorporating both the elastic and the fibers.

FIG. 3 is a similar view in which the elastic is inlaid.

FIG. 4 is a schematic view illustrating the method of knitting in the elastic.

FIG. 5 is a similar view showing inlaying the elastic.

Now referring to FIG. l, courses 10, 12, 14 and 16 are drawn from an inelastic yarn 17 which is taken by every needle, but only every other needle of which takes fibers to draw them along with the yarn 17. Thus fibers are formed into tufts 18 at alternate wales 19, 21, 23 and 25.

An elastic yarn 17', either covered or uncovered, preferably the former, is drawn into knitted stitches at these alternate wales and in alternate courses thus appearing at spaced courses 11, 13 and 15, at least in theory and sequence, although in actual practice such a yarn being very extensible and contractile will draw up as the fabric is released whereupon its loops more or less lose their identity as such.

This fabric can be extended in either direction as the elastic is stretched laterally with the base fabric. Since it contracts and draws the fabric together, wales 20, Z2 and 24 will be pushed to the front as the wales with the pile are drawn closer together. For that reason one may control the cover of the pile so it need be inserted in spaced wales only for many purposes.

When extending the cloth walewise, loops of elastic are .reformed and are extended thus permitting the fabric to elongate.

Normally, inelastic fabrics of this type are knitted fairly tightly so that the tufts will notfcome out during treatment, use, washings, etc. The extension of the fabric might well result in loosening the pile but to prevent that, the elastic yarn is so positioned that it draws the loops and tufts of one course into contact with those of a next course so that a pinching and frictioning condition is set up thereby to hold the tufts in place.

In FIG. 2 a similar fabric structure is shown, but this fabric, although it has spaced courses 26, 28 and 30 knitted from non-elastic yarn Y and intermediate courses 27, 2-9 and 31 from elastic yarn Y', the arrangement is one of staggering elastic loops and also pile tufts 18 so they appear in alternate wales 32, 34 and 36 in courses 28 and those alternate courses following, but in Wales 33, 35 and 37 in courses 26, 30, etc. In some instances this may give a better cover and presents an appearance of uniformity when stretched well as when contracted.

In FIG. 3 pile tufts 18 are, formed on every stitch in each course of non-elastic yarn 38 and elastic yarn 38 1s inlaid at alternate wales 39, 41 and 43 being floated in back of intermediate wales 40, 42, etc. Here we have elastic every other course, but it is to be understood that elastic yarn may be inlaid every course or spaced differently as the occasion may demand or make more-,advisable.

The extensibility here is mainly in `a lateraldirection, but the elastic inlaid and floated` as shown still assists in holding the tufts -in place as the fabric is` extended 'and the elastic drawn more tightly into frictional contact with its surrounding material.`

In. FIG. 4 mechanism adapted to knitthe fabric of FIG. l is shown. -An open top, independent needle machine is employed in which a complement of needles 44 are carried in the usual needle cylinder and cooperate with sinkers (not shown). Needles are raised to take fibers from a doffer cylinder 45, a base yarn 17 fed in any convenient Way as from a guide 47 and to be drawn down to knit by cams (not shown) in a cam ring 48. Here, a needle division is eifectedin any convenient manner as by arranging the butts thereon alternately as long and short butts. As illustrated, alternate needles. are raised higher thanintermediate ones and take tufts of fibers. The intermediate needles areraised to a position to clear their-latches and takev the yarn 17. Needles'raised to take the fibers must not be` raised to such a height that they cleartheir latches above the feeding yarn 17. Both long and short butt needles-are drawn down to knit and draw stitches ofthe base yarn with a tuft at every other loop.

At a following feeding stationan elastic yarn 17' is fed by a guide S0 and here long -butt needles only are raised to clear their latches, take the elastic yarn and knit. Of'course, a multifed knitter will have a number of each of these feeding stations alterna-tely'arrangedV and preferably the elastic feeding means is to be interposed between the usual, more involvedcards and feeding sta'- tions atrwhich the base yarn and pile tuftsV are-presented and incorporated in the fabric.

To knit the fabric of FIG; 2, an alternating arrangement is shown and preferably, needlesl should be provided with a number of butts or jacks. With the latter, all needle butts may be of uniform length and jacks used selectively to cause both the pile and; the-elastic yarn to be taken by alternate needles at one pair of feeds, but at intermediate needles on the next pair, etc. Of course, those skilled in the art will recognize the fact that many different variations may be forthcoming and the skilled knitter should understand the manner in whicha jack pattern could be set up to accomplish the knitting of such variations.

To knit the fabric of FIG. 3, an elastic yarn 38 is fed from a guide 51, IFIG. 5, in advance of what may be termed a main feedingrstation and is presented in such position that selected needles receive` that yarn below their latches. At the following station a card dolfer roll 52 presentsV parallelized sliver to either all or to spaced needles as is desiredk whereupon all needlesV then take va base yarn 38 fed from tube 54 and knit that yarn at the same time inlaying the elastic and incorporating the fibers as pile,A

Here the needles which do not receive the elastic thread below their latches pass in front of that thread as they vare raised to take their fibers and yarn 38. All needles draw a tuft, but the elastic is laidin to be held at every other Wale. Of coursse, it may be spaced to be held at more widely spaced loops and may Skip courses in which casean elastic feeding guide would precede every other base yarn feed or every third or fourth feed, etc.

Likewise, the saine or a different needle division may be availed .of to space needles raised to takeV the fibers.

The base fabric may be knitted from any relatively non-elastic yarn such as cotton, animal fibers or artificial filaments 0,1", ill. $9.111@ instances itnnay be to advantageto employ a yarn of the type having considerable Aextensibility although it does not classify as one of the elastic yarns in which rubber in some form, either natural or synthetic is to be found. Any one of the nylon type yarns or other so-called stretch yarns may be used. In some instances where not too great provision for stretch is desired, such a stretch yarn may be employed instead of the covered or other rubber yarn which has been described by Way of setting forth the preferred form which the invention may take.

Spacing of the elastic yarn both coursewise and walewise is capable of rather widevariation but the tension under which it is incorporated should be maintained at such level that it kcontracts vto a considerable extent in order to impart the necessary characteristics of stretchability and recovery to the fabric and also, to tighten the stitches so that the tufts of pile will be held in both when the fabric is maintained in relaxed and in extended condition.

By the term discrete tufts of staple bers in the claims is meant a mass of separate or individual fibers, a group of which is taken by the knitting instrumentalities to be knitted en masse with the base and elastic yarns.

While one embodiment and modifications` of the invention have been disclosed, it is to be understood -that the inventive concept may be carried out in a number of ways. This invention is, therefore, not to be limited to the precise details described, but is intended to embrace all variations and modifications thereof falling within the spirit of the invention and the scope of the claims.

I claimt.

1. In a knitted fabric the combination of a base fabric coursesr of which are formed from a relatively non-elastic yarn and an elastic yarn, said elastic yarn being incorporated to be held in the-fabric at spaced wales only, and a pile at one face of the fabric comprised as a multiplicity of discrete tufts of staple fibers and incorporated into the fabric with loopsl drawn coincidentally with some at least of the loops ofnon-elastic yarn and further being heldV in place by the contracted elastic yarn.

2. In a knitted fabric the combination of a base-fabric courses of which are formed from a relatively non-elastic yarn and an elastic yarn, said elastic yarn being incorporated to be held in the fabric at spaced courses only, and a pile at one face of the fabric comprised as a multiplicity of discrete tufts of staple fibers and'incorporated into the fabric with loops drawn coincidentally with some at least of the loops of non-elastic yarn and further being held in place by the contracted elastic yarn. a

3. In a knitted fabric the combination of a base fabric courses of which are formed from a relatively non-elastic yarn and an elastic yarn, said elastic yarn being incorporated to be held in the fabric at spaced courses and at spaced Wales only, and a pile at one face of the fabric comprised as a multiplicity of discrete tufts of staple fibers and incorporated into the fabric with loops drawn coincidentally with some at least of the loopsv of nonelastic yarn and further being held in place by the contracted elastic yarn.

4. In a knitted fabric the combination of a base fabric courses of which areV formedV from a relatively non-elastic yarn and an elastic yarn, said elastic yarn being incorporated to be held in the fabricat spaced wales only, and a pile at one face of the fabric comprised as a multiplicity of discrete tufts of staple fibers and incorporated into the fabric with loops alternating in Wales and courses and drawn coincidentally with some at least of the loops of non-elastic yarn and further being held in place by the d elastic arn. i mgrtnethod ofI forming anY elastic, knittedpile f abric which comprises the steps of forming a basefabrieby feeding a non-elastic yarn to needles of a knitting machine and simultaneouslyv drawing tufts of staple fibers along with at least some of the loops of non-elastic yarn, and incorporating an elastic yarn to be held in at least some of the courses and some of the Wales of said base References Cited in the le of this patent fabric and -to hold said tufts of staple bers in place. UNITED STATES PATENTS 6. A method as defined in claim 5 wherein said elastic yarn is incorporated by knitting it into stitches drawn sirson 1189 through non-elastic yarn stitches. 5 n A 21 1942 7. A method as defined in claim 5 wherein said elastic 2280536 Moore pr. yarn is incorporated by inlaying it to be held at spaced FOREIGN PATENTS non-elastic yarn stitches. 367,230 Germany Jan. 18, 1923 

1. IN A KNITTED FABRIC THE COMBINATION OF A BASE FABRIC COURSES OF WHICH ARE FORMED FROM A RELATIVELY NON-ELASTIC YARN AND AN ELASTIC YARN SAID ELASTIC YARN BEING INCORPORATED TO BE HELD IN THE FABRIC AT SPACED WALES ONLY, AND A PILE AT ONE FACE OF THE FABRIC COMPRISED AS A MULTIPLICITY OF DISCRETE TUFTS OF STAPLE FIBERS AND INCORPORATED INTO THE FABRIC WITH LOOPS DRAWN COINCIDENTALLY WITH SOME AT LEAST OF THE LOOPS OF NON-ELASTIC YARN AND FURTHER BEING HELD IN PLACE BY THE CONTRACTED ELASTIC YARN. 